Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | 138-7575 | Link Bracket | 3 |
B | 422-8733 | Jack Stand Gp | 3 |
C | 1U-9202 | Lever Puller Hoist | 1 |
D | 1P-1863 | Retaining Ring Pliers | 1 |
E | 308-3470 | Jack Stand Gp | 2 |
F | 140-7742 | Sleeve | 1 |
H | FT-2769 | Table | 1 |
J | 4C-8156 | Lifting Fixture | 1 |
L | 9U-7480 | Compressing Tube | 1 |
8T-4133 | Nut | 1 | |
8T-4224 | Hard Washer | 1 | |
- | Threaded Rod M10 - 1.5 by 460mm |
1 | |
N | 2P-8312 | Retaining Ring Pliers | 1 |
R | 189-0408 | Shackle As | 1 |
3E-3882 | Eyebolt | 1 | |
T | 4C-4030 | Loctite 242 Thread Locker | 1 |
NOTICE |
---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected always.
Note: Lubricate all seal rings and O-ring seals prior to assembly.
Note: Check the O-ring seals, and the seals for wear or for damage. Replace the components, if necessary.
Note: Remove old anaerobic sealant from the bottom of the blind tapped holes in housing (237) before assembling.
- Install filter (246) and O-ring seal (245). Position cover (244) and install bolts (243). Tighten bolts (243) to a torque of
28 ± 7 N·m (21 ± 5 lb ft) .Show/hide tableIllustration 2 g01389019 - Position plate (241) and install bolts (242). Tighten bolts (242) to a torque of
12 ± 3 N·m (106 ± 27 lb in) . - Lower the temperature of bearing outer races (240), (239), and (238). Install bearing outer races (240), (239), and (238) into housing (237).
Show/hide table
Illustration 3 g01389010 - Install the O-ring seals and covers (236) onto housing (49). Tighten the bolts for covers (236) to a torque of
28 ± 7 N·m (21 ± 5 lb ft) . Install the O-ring seals and covers (235) onto housing (49). Tighten the bolts for covers (235) to a torque of28 ± 7 N·m (21 ± 5 lb ft) .Show/hide tableIllustration 4 g01394193 - Lower the temperature of races (234) and races (233) . Install races (234) and races (233) into housing (49).
Show/hide table
Illustration 5 g01394189 - Install O-ring seal (232).
Show/hide table
Illustration 6 g01394188 - Raise the temperature of bearing (231). Install bearing (231). Install retaining ring (230).
Show/hide table
Illustration 7 g01394185 - Install gear (229).
- Install retaining ring (228).
Show/hide table
Illustration 8 g01394184 - Install retainer (227). Install bearing (226). Install retaining ring (225).
Show/hide table
Illustration 9 g01394180 - Install gear (224). Install bolts (223). Tighten bolts (223) to a torque of
28 ± 7 N·m (21 ± 5 lb ft) .Show/hide tableIllustration 10 g01394236 - Use two people to position shaft assembly (130) onto Tooling (H). The weight of input shaft assembly (130) is approximately
25 kg (55 lb) . Use suitable blocking to support input shaft assembly (130). Install retaining ring (222) (not shown) onto input shaft assembly (130). Install gear (221). Raise the temperature of inner bearing (220). Install inner bearing (220) onto input shaft assembly (130).Show/hide tableIllustration 11 g01394368 - Use a suitable lifting device to position input shaft assembly (130) to housing (237). The weight of input shaft assembly (130) is approximately
23 kg (50 lb) . Use Tooling (N) to install retaining ring (219) onto input shaft assembly (130). Install ring seal (218).Show/hide tableIllustration 12 g01388797 Show/hide tableIllustration 13 g01394379 - Install seal rings (217) and (216) onto piston (215).
Show/hide table
Illustration 14 g01388786 - Install piston (215) and valve assembly (214) onto clutch assembly (174).
Show/hide table
Illustration 15 g01388754 - Install friction discs (213) and clutch plates (212) onto clutch assembly (174). Install friction disc (211), spring (210), and hub assembly (207) onto clutch assembly (174).
Show/hide table
Illustration 16 g01388732 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Use Tooling (L) to compress hub assembly (207). Install two half rings (209) (not shown) and lock rings (208) onto clutch assembly (174).
Show/hide table
Illustration 17 g01388726 - Position washer (205) to clutch assembly (174). Apply Tooling (T) to screws (206). Install screws (206). Tighten screws (206) to a torque of
12 ± 3 N·m (106 ± 27 lb in) .Show/hide tableIllustration 18 g01388685 - Install thrust disc (204) and roller bearing assembly (203) onto clutch assembly (174).
Show/hide table
Illustration 19 g01388678 - Install gear assembly (202), thrust disc (201), thrust disc (200), and thrust race (199) onto clutch assembly (174). Raise the temperature of inner bearing (198). Install inner bearing (198) onto clutch assembly (174).
- Use a suitable lifting device to turn over clutch assembly (174) onto Tooling (H). The weight of clutch assembly (174) is approximately
43 kg (95 lb) .Show/hide tableIllustration 20 g01388663 Show/hide tableIllustration 21 g01394424 - Install seal rings (196) and (197) onto piston (195).
Show/hide table
Illustration 22 g01388653 - Install piston (195) and valve assembly (194) onto clutch assembly (174).
Show/hide table
Illustration 23 g01388635 - Install friction discs (191), clutch plates (192), friction discs (193), spring (190), and hub assembly (187) onto clutch assembly (174).
Show/hide table
Illustration 24 g01388624 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Use Tooling (L) to compress hub assembly (187). Install two half rings (189) (not shown) and lock rings (188).
Show/hide table
Illustration 25 g01388618 - Position washer (185) to clutch assembly (174). Apply Tooling (T) to screws (186). Install screws (186). Tighten screws (186) to a torque of
12 ± 3 N·m (106 ± 27 lb in) .Show/hide tableIllustration 26 g01388614 - Install thrust disc (184) and roller bearing assembly (183) onto clutch assembly (174).
Show/hide table
Illustration 27 g01388597 - Install gear assembly (182), thrust disc (181), and thrust disc (180) onto clutch assembly (174). Raise the temperature of inner bearing (179). Install inner bearing (179) onto clutch assembly (174).
Show/hide table
Illustration 28 g01394545 - Attach Tooling (R) and a suitable lifting device to clutch assembly (174). The weight of clutch assembly (174) is approximately
64 kg (140 lb) . Use Tooling (R) and the suitable lifting device to install clutch assembly (174) to housing (237).Show/hide tableIllustration 29 g01388581 - Install O-ring seals (177) and seal rings (178) onto seal carrier (176).
Show/hide table
Illustration 30 g01388568 - Position seal carrier (176) onto clutch assembly (174). Install bolts (175). Tighten bolts (175) to a torque of
55 ± 10 N·m (41 ± 7 lb ft) .Show/hide tableIllustration 31 g01388470 Show/hide tableIllustration 32 g01394550 - Install seal rings (173) and (172) onto piston (171).
Show/hide table
Illustration 33 g01388335 - Install piston (171) and valve assembly (170) onto clutch assembly (135).
Show/hide table
Illustration 34 g01388330 - Install friction discs (169), clutch plates (168), friction disc (167), spring (166), and hub assembly (163) onto clutch assembly (135).
Show/hide table
Illustration 35 g01388324 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Use Tooling (L) to compress hub assembly (163). Install two half rings (165) (not shown) and lock rings (164).
Show/hide table
Illustration 36 g01388320 - Position washer (162) to clutch assembly (135). Apply Tooling (T) to screws (161). Tighten screws (161) to a torque of
12 ± 3 N·m (106 ± 27 lb in) .Show/hide tableIllustration 37 g01388296 - Install thrust disc (160) and roller bearing (159) onto clutch assembly (135).
Show/hide table
Illustration 38 g01388277 - Install gear assembly (158). thrust disc (157), thrust disc (156), and thrust race (155) onto clutch assembly (135). Raise the temperature of inner bearing (154). Install inner bearing (154) onto clutch assembly (135).
- Use a suitable lifting device to turn over clutch assembly (135) onto Tooling (H). The weight of clutch assembly (135) is approximately
41 kg (90 lb) .Show/hide tableIllustration 39 g01388246 Show/hide tableIllustration 40 g01394572 - Install seal rings (153) and (152) onto piston (151).
Show/hide table
Illustration 41 g01394574 - Install piston (151) and wave spring (150) onto clutch assembly (135).
Show/hide table
Illustration 42 g01388240 - Install clutch plates (149), friction discs (148), and hub assembly (145).
Show/hide table
Illustration 43 g01388208 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Use Tooling (L) to compress hub assembly (145). Install two half rings (147) (not shown) and lock rings (146).
Show/hide table
Illustration 44 g01388185 - Lower the temperature of bearing (144). Install bearing (144) into gear assembly (141).
Show/hide table
Illustration 45 g01388168 - Install washer (143), thrust disc (142), gear assembly (141), thrust disc (140), and spacer (139) onto clutch assembly (135).
Show/hide table
Illustration 46 g01394607 - Install gear (138) and spacer (137) onto clutch assembly (135). Raise the temperature of inner bearing (136). Install inner bearing (136).
Show/hide table
Illustration 47 g01394616 - Attach Tooling (R) and a suitable lifting device to clutch assembly (135). The weight of clutch assembly (135) is approximately
61 kg (135 lb) . Use Tooling (R) and the suitable lifting device to install clutch assembly (135) into housing (237).Show/hide tableIllustration 48 g01394625 - Install O-ring seals (134) and seal rings (133) onto seal carrier (132).
Show/hide table
Illustration 49 g01394631 - Position seal carrier (132) onto clutch assembly (135). Install bolts (131). Tighten bolts (131) to a torque of
55 ± 10 N·m (41 ± 7 lb ft) .Show/hide tableIllustration 50 g01394649 - Install gear (129) onto input shaft assembly (130). Raise the temperature of inner bearing (128). Install inner bearing (128) onto input shaft assembly (130).
Show/hide table
Illustration 51 g01387858 Show/hide tableIllustration 52 g01394705 - Install seal rings (127) and (126) onto piston (125).
Show/hide table
Illustration 53 g01394707 - Install piston (125) and wave spring (124) onto clutch assembly (60).
Show/hide table
Illustration 54 g01387846 - Install clutch plates (123), friction discs (122), and hub assembly (119).
Show/hide table
Illustration 55 g01387824 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Use Tooling (L) to compress hub assembly (119). Install two half rings (121) (not shown) and lock rings (120).
Show/hide table
Illustration 56 g01387820 - Install washer (118) and thrust disc (117).
Show/hide table
Illustration 57 g01387765 - Lower the temperature of bearing (116). Install bearing (116) into gear assembly (115).
Show/hide table
Illustration 58 g01394711 - Install gear assembly (115) and thrust disc (114) onto clutch assembly (60).
Show/hide table
Illustration 59 g01394713 - Install gear (113) and thrust disc (112) onto clutch assembly (60). Raise the temperature of inner bearing (111). Install inner bearing (111) onto clutch assembly (60).
- Use a suitable lifting device to turn over clutch assembly (60) onto Tooling (H). The weight of clutch assembly (60) is approximately
54 kg (120 lb) .Show/hide tableIllustration 60 g01387580 Show/hide tableIllustration 61 g01394729 - Install seal rings (110) and (109) onto piston (108).
Show/hide table
Illustration 62 g01387573 - Install piston (108) and wave spring (107) onto clutch assembly (60).
Show/hide table
Illustration 63 g01387556 - Install clutch plates (106), friction discs (105), and hub assembly (102) onto clutch assembly (60).
Show/hide table
Illustration 64 g01387541 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Use Tooling (L) to compress hub assembly (102). Install two half rings (104) (not shown) and lock rings (103).
Show/hide table
Illustration 65 g01387528 - Install washer (101) and thrust disc (100) onto clutch assembly (60).
Show/hide table
Illustration 66 g01387526 - Lower the temperature of sleeve bearing (99). Install sleeve bearing (99) into gear assembly (98).
Show/hide table
Illustration 67 g01387520 - Install gear assembly (98) and thrust disc (97) onto clutch assembly (60).
Show/hide table
Illustration 68 g01394799 - Install gear (96) and thrust disc (95) onto clutch assembly (60). Raise the temperature of inner bearing (94). Install inner bearing (94) onto clutch assembly (60).
Show/hide table
Illustration 69 g01394809 - Install seal rings (93) and (92) onto piston (91).
Show/hide table
Illustration 70 g01394820 - Install seal ring (89) onto balance piston (88).
Show/hide table
Illustration 71 g01394812 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install piston (91), springs (90), and balance piston (88) onto clutch assembly (59). Use Tooling (N) to install retaining ring (87) onto clutch assembly (59).
Show/hide table
Illustration 72 g01387232 - Install clutch plates (86), friction discs (85), and hub assembly (84).
Show/hide table
Illustration 73 g01387228 - Install lock rings (83), half rings (82), washer (81), and thrust disc (80).
Show/hide table
Illustration 74 g01394862 - Install gear assembly (79), thrust disc (78), and thrust washer (77). Raise the temperature of bearing (76). Install bearing (76).
- Use a suitable lifting device to turn over clutch assembly (59). The weight of clutch assembly (59) is approximately
59 kg (130 lb) .Show/hide tableIllustration 75 g01394871 Show/hide tableIllustration 76 g01387093 - Install seal rings (74) and (75) onto piston (73). Install piston (73) and wave spring (72).
Show/hide table
Illustration 77 g01387088 - Install clutch plates (71), friction discs (70), and hub assembly (67).
Show/hide table
Illustration 78 g01386997 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Use Tooling (L) to compress hub assembly (67). Install two half rings (69) (not shown) and lock rings (68).
Show/hide table
Illustration 79 g01386993 - Install thrust washer (66).
Show/hide table
Illustration 80 g01386992 - Lower the temperature of bearing sleeves (65). Install bearing sleeves (65) into gear assembly (63).
Show/hide table
Illustration 81 g01386841 - Install gear assembly (63) and thrust washer (64).
Show/hide table
Illustration 82 g01394888 - Raise the temperature of rotor (62). Install rotor (62) onto clutch assembly (59).
- Raise the temperature of bearing (61). Install bearing (61) onto clutch assembly (59).
Show/hide table
Illustration 83 g01386815 Show/hide tableIllustration 84 g01386811 - Attach Tooling (J) and a suitable lifting device to clutch assembly (59) and clutch assembly (60). The combined weight of clutch assembly (59) and clutch assembly (60) is approximately
163 kg (360 lb) . Use Tooling (J) and the suitable lifting device to move clutch assembly (59) and clutch assembly (60) from Tooling (H) to the housing.Show/hide tableIllustration 85 g01395925 - Install seal rings (57) and O-ring seals (58) to seal carrier (56). Repeat for the remaining seal carrier.
Show/hide table
Illustration 86 g01386795 - Position seal carrier (56) and install bolts (55). Tighten bolts (55) to a torque of
55 ± 10 N·m (41 ± 7 lb ft) . - Position seal carrier (54) and install bolts (53). Tighten bolts (53) to a torque of
55 ± 10 N·m (41 ± 7 lb ft) .Show/hide tableIllustration 87 g01386792 - Install the O-ring seal and tube assembly (52). Install bolts (51) and the locks. Tighten bolts (51) to a torque of
55 ± 10 N·m (41 ± 7 lb ft) .Show/hide tableIllustration 88 g01386764 - Attach Tooling (A) and Tooling (C) to housing (49). The weight of housing (49) is approximately
136 kg (300 lb) . - Use Tooling (A), Tooling (C), and the suitable lifting device to position housing (49). Install bolts (48). Tighten bolts (48) to a torque of
55 ± 10 N·m (41 ± 7 lb ft) .Show/hide tableIllustration 89 g01386757 - Position speed sensors (47) and (46). Install bolts (45). Tighten bolts (45) to a torque of
28 ± 7 N·m (21 ± 5 lb ft) .Show/hide tableIllustration 90 g01386749 - Install cover (44).
Show/hide table
Illustration 91 g01386747 - Position speed sensors (43) and (42). Install bolts (41). Tighten bolts (41) to a torque of
28 ± 7 N·m (21 ± 5 lb ft) .Show/hide tableIllustration 92 g01386730 - Position speed sensor (39) and guard (40). Install bolt (38). Tighten bolt (38) to a torque of
28 ± 7 N·m (21 ± 5 lb ft) .Show/hide tableIllustration 93 g01386684 This Illustration shows the transmission with the output shaft downward. - Attach Tooling (A), Tooling (C), Tooling (F), and a suitable lifting device to transmission (1). Use Tooling (A), Tooling (C), Tooling (F), and the suitable lifting device to position transmission (1) onto Tooling (B) and Tooling (E) with the output shaft upward. The weight of transmission (1) is approximately
861 kg (1900 lb) .Show/hide tableIllustration 94 g01386675 - Install hub (37) and retaining ring (36).
Show/hide table
Illustration 95 g01386663 - Install dowels (35) and O-ring seals (34).
- Install clutch plates (33) and friction discs (32).
Show/hide table
Illustration 96 g01386662 - Install seal (31).
Show/hide table
Illustration 97 g01395990 - Install O-ring seal (30), O-ring seal (29), O-ring seal (28), O-ring seal (27), and O-ring seal (26) onto solenoid (25).
Show/hide table
Illustration 98 g01386646 - Install solenoid (25). Install pressure sensor (24) and the O-ring seal. Tighten pressure sensor (24) to a torque of
60 ± 6 N·m (44 ± 4 lb ft) .Show/hide tableIllustration 99 g01386632 - Use two people to install housing (23). The weight of housing (23) is approximately
20 kg (45 lb) .Show/hide tableIllustration 100 g01386624 - Install guard (20). Connect harness assembly (21) and harness assembly (19).
Show/hide table
Illustration 101 g01396019 - Install piston seal (18) and piston seal (17) onto piston (16).
Show/hide table
Illustration 102 g01386610 - Install piston (16) and O-ring seal (15).
Show/hide table
Illustration 103 g01386599 - Install coned disc springs (14). Use Tooling (D) to install retaining ring (13).
Show/hide table
Illustration 104 g01386589 - Install lip seal (12).
Show/hide table
Illustration 105 g01386585 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Position plate assembly (11). Install bolts (10). Tighten bolts (10) to a torque of
100 ± 20 N·m (74 ± 15 lb ft) .Show/hide tableIllustration 106 g01386579 This Illustration shows the transmission with the output shaft upward. - Attach Tooling (A), Tooling (C), and a suitable lifting device to transmission (1). The weight of transmission (1) is approximately
853 kg (1880 lb) .Show/hide tableIllustration 107 g01386575 - Install O-ring seal (9) and cup (8). Install retaining ring (7).
Show/hide table
Illustration 108 g01386574 - Install yoke assembly (6).
Show/hide table
Illustration 109 g01386565 Show/hide tableIllustration 110 g01386568 - Attach Tooling (A) and a suitable lifting device to transmission (1). The weight of transmission (1) is approximately
857 kg (1890 lb) . Use Tooling (A) and the suitable lifting device to position transmission (A) onto Tooling (B). - Position spacers (5) and control module (4). Install bolts (3). Tighten bolts (3) to a torque of
28 ± 7 N·m (21 ± 5 lb ft) . - Install hose assembly (2).
![]() | |
Illustration 1 | g01389210 |
This Illustration is viewed from the bottom. |
End By:
- Install the transmission.